Cutting insert, cutting tool, and method for manufacturing a cut workpiece

ABSTRACT

This cutting insert is provided with a lower surface of polygonal shape including side parts and a pair of corner parts, an upper surface, a lateral surface situated between the lower surface and the upper surface, a pair of corner cutting edges located at the pair of corners, and a main cutting edge located in a side portion. The main cutting edge is upwardly convex in shape, and in side view includes an upwardly convex curving portion, and a pair of linear portions respectively extending toward the pair of corner cutting edges from the curving portion. The top portion of the curving portion is positioned more toward the one of the corner cutting edges which, of the pair of corner cutting edges, is that contiguous to a working surface of a work material during cutting of the work material.

The present invention is a continuation of U.S. application Ser. No.14/900,058 filed on Dec. 18, 2015 which is a National Phase entry ofInternational Application No. PCT/JP2014/066603, filed on Jun. 24, 2014,which claims the benefit of Japanese Application No. 2013-134716, filedon Jun. 27, 2013 and Japanese Application No. 2013-231827, filed on Nov.8, 2013. The contents of the above applications are incorporated byreference herein in their entirety.

TECHNICAL FIELD

The present invention relates to a cutting insert, a cutting tool, and amethod for manufacturing a cut workpiece.

BACKGROUND ART

In the related art, the cutting inserts disclosed in Patent Documents 1to 4 and the like are known as cutting inserts used in cut processing ona work material. Specifically, the cutting inserts disclosed in PatentDocuments 1 to 4 are used in milling processing such as face milling orend milling. The cutting insert disclosed in Patent Document 4 has acutting edge curved to be upwardly convex when viewed from the side.

Regarding the cutting inserts, as illustrated in FIG. 1, the largestimpact is applied to a cutting insert 10 in a case where the angleformed by a ridge e1 of a cutting edge with respect to an end surface Sof a work material 200 is small when the cutting insert 10 starts to cutinto the work material 200 when viewed from above, that is, in a casewhere the entire ridge e1 of the cutting edge strikes the end surface Sof the work material 200. When the impact applied to the cutting insertis increased, a large impact is transmitted between the cutting insertand the work material and chatter vibration is generated. Then, when thechatter vibration becomes very large, there is a risk of damaging thecutting insert or cutting tool.

In the cutting insert disclosed in Patent Document 4, the cutting edgehas a convex curved shape which curves upward when viewed from the side.In such a case, the chatter vibration can be reduced because the impactapplied to the cutting insert can be controlled to be smaller when thecutting insert starts to cut into the work material. However, becausethe total length of the cutting edge in the cutting insert disclosed inPatent Document 4 is long in comparison with a cutting insert where thecutting edge has a linear shape when viewed from the side, the contactlength of the cutting edge becomes long with respect to the workmaterial. As a result, the time during which cutting force continues tobe applied to the cutting insert is also increased.

The present invention has been made in view of the above problems. Anobject of the present invention is to provide a cutting insert, acutting tool, and a method for manufacturing a cutting tool and a cutworkpiece, which can suppress chatter vibration and control increases inthe cutting resistance when the cutting insert starts to cut into a workmaterial.

Patent Literature 1: Japanese Unexamined Patent Application PublicationNo. 2006-75913A

Patent Literature 2: Japanese Unexamined Patent Application PublicationNo. 2006-88332A

Patent Literature 3: Japanese Unexamined Patent Application Publication(Translation of PCT Application) No. 2010-523352A

Patent Literature 4: Japanese Unexamined Patent Application PublicationNo. H09-225724A

SUMMARY OF INVENTION

A cutting insert based on one aspect of the present invention isprovided with an upper surface with a polygonal shape including sideportions and a pair of corner parts adjacent to the side parts; a lowersurface with a polygonal shape corresponding to the upper surface; alateral surface connecting between the lower surface and the uppersurface; a pair of corner cutting edges located at the pair of cornersat a line of intersection of the upper surface and the lateral surface;and a main cutting edge located in the side portion at a line ofintersection of the upper surface and the lateral surface, the cuttinginsert being used for cutting a work material. The main cutting edge isupwardly convex in shape and in side view includes an upwardly convexcurving portion and a pair of linear portions respectively extendingtoward the pair of corner cutting edges from the curving portion. An topportion of the curving portion is positioned more toward the one of thecorner cutting edges which, of the pair of corner cutting edges, iscontiguous to the machined surface of the work material when cutting thework material.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a planar schematic diagram illustrating a state when a cuttingedge ridge of a cutting insert starts to cut into an end surface of awork material. Here, the point where the one-dot chain lines intersectin FIG. 1 is a rotation center axis Y of the cutting tool and the dottedline shows the outer edge of the rotation locus of the cutting inserts.

FIG. 2 is a perspective diagram illustrating the cutting insert of oneembodiment of the present invention.

FIG. 3 is a planar diagram of the cutting insert illustrating in FIG. 2.

FIG. 4 is a lateral surface diagram of the cutting insert illustratingin FIG. 2.

FIG. 5 is a lateral surface diagram in which the cutting insertillustrated in FIG. 4 is enlarged.

FIG. 6 is a perspective diagram illustrating a cutting insert accordingto a modification.

FIG. 7 is a planar diagram of the cutting insert illustrated in FIG. 6.

FIG. 8 is a planar diagram in which the cutting insert illustrated inFIG. 7 is enlarged.

FIG. 9 is a lateral surface diagram of the cutting insert illustrated inFIG. 6.

FIG. 10 is a perspective diagram illustrating a cutting tool of oneembodiment of the present invention.

FIG. 11 is a lateral surface diagram of the cutting tool illustrated inFIG. 10.

FIG. 12 is a lateral surface diagram in which a part of the cutting toolillustrated in FIG. 11 is enlarged.

FIG. 13 is a perspective diagram illustrating one step in a method formanufacturing a cut workpiece of one embodiment of the presentinvention.

FIG. 14 is a perspective diagram illustrating one step of the method formanufacturing a cut workpiece of one embodiment of the presentinvention.

FIG. 15 is a perspective diagram illustrating one step of the method formanufacturing a cut workpiece of one embodiment of the presentinvention.

DESCRIPTION OF EMBODIMENTS

<Cutting Insert>

Description will be given below of a cutting insert 1 of one embodiment(referred to below simply as the insert 1) using FIGS. 2 to 5. Here, thetwo-dot chain line in FIG. 2 indicates the center axis X of the insert1. FIG. 5 is a lateral surface diagram in which a part of the lateralsurface of the insert 1 in FIG. 4 is cut away and enlarged.

As illustrated in FIGS. 2 to 5, the insert 1 of the present embodimentis a throw-away tip, and is provided with a lower surface 2, an uppersurface 3, a lateral surface 4 connecting with the lower surface 2 andthe upper surface 3, a pair of corner cutting edges 5 (5 a and 5 b)located at a line of intersection between the upper surface 3 and thelateral surface 4, and a main cutting edge 6 located between the pair ofcorner cutting edges 5 (5 a and 5 b). The main cutting edge 6 includesan upwardly convex shape and has an upwardly convex curving portion 61,and a pair of linear portions 62 respectively extending toward the pairof corner cutting edges 5 (5 a and 5 b) from the curving portion 61 inside view.

In addition, an top portion 63 located uppermost in the curving portion61 of the main cutting edge 6 is positioned more toward the one cornercutting edge 5 a which, of the pair of corner cutting edges 5 a and 5 b,is contiguous to the machined surface of the work material when cuttingthe work material. Out of the pair of corner cutting edges 5 a and 5 b,the cutting edge contiguous to the machined surface of the work materialwhen cutting the work material is the first corner cutting edge 5 a andthe cutting edge located to be separated from the machined surface ofthe work material when cutting the work material is the second cornercutting edge 5 b. At this time, the top portion 63 is positioned moretoward the first corner cutting edge 5 a than the second corner cuttingedge 5 b out of the pair of corner cutting edges 5 a and 5 b.

The upper surface 3 includes a polygonal shape and has side parts and apair of corner parts adjacent to the side parts. In addition, the lowersurface 2 has a polygonal shape corresponding to the upper surface 3.The lower surface 2 and the upper surface 3 of the insert 1 in thepresent embodiment respectively have rectangular shapes including aplurality of corner parts. The corner parts in the present embodimentare not corners in the strict sense, but shapes curved when viewed fromabove.

A through-hole H is formed to pass vertically through the insert 1. Thethrough-hole H is formed from the central portion of the upper surface 3to the central portion of the lower surface 2. The through-hole H is ahole through which a screw is passed and is used in order to fix theinsert 1 to a holder by fastening the screw into the holder. Here, thethrough-hole has a circular shape when viewed from above and thediameter thereof is, for example, from 2 to 12 mm.

Because the through-hole H is formed from the center of the uppersurface 3 to the center of the lower surface 2, the center axis X of thethrough-hole H extends in the up and down direction. Therefore, in thefollowing, a virtual plane L perpendicular to the center axis X is setin order to evaluate the position in the up and down direction of eachof the constituent components in the cutting insert 1 of the presentembodiment.

Examples of the material of the insert 1 include cemented carbide alloy,cermet, or the like. As the composition of the cemented carbide alloy,for example, there are WC-Co produced by adding cobalt (Co) powder totungsten carbide (WC) and carrying out sintering, WC—TiC—Co in whichtitanium carbide (TiC) is added to WC—Co, or WC—TiC—TaC-Co in whichtantalum carbide (TaC) is added to WC—TiC—Co. In addition, cermet is asintered composite material in which metal is composite with a ceramiccomponent and specific examples thereof include titanium compounds inwhich titanium carbide (TiC) or titanium nitride (TiN) is the maincomponent.

The surface of the insert 1 may be coated with a coating film using achemical vapor deposition (CVD) method or a physical vapor deposition(PVD) method. Examples of the composition of the coating film includetitanium carbide (TiC), titanium nitride (TiN), titanium carbonitride(TiCN), alumina (Al₂O₃), and the like.

In the insert 1, the maximum width of the lower surface 2 or the uppersurface 3 is from 5 to 20 mm. In addition, the height from the lowersurface 2 to the upper surface 3 is from 2 to 8 mm. Here, the shapes ofthe upper surface 3 and the lower surface 2 are not limited to those ofthe embodiment described above. For example, the shape of the uppersurface 3 when viewed from above may be a polygonal shape such as atriangle, a pentagon, a hexagon, or an octagon.

As illustrated in FIG. 2, the upper surface 3 includes a land surface31, a rake face 32, and a flat surface 33. The land surface 31 iscontinuous with the corner cutting edges 5 and the main cutting edge 6.The corner cutting edges 5 and the main cutting edge 6 correspond to theouter edge of the upper surface 3. The rake face 32 is provided in aregion closer to the through-hole H than the land surface 31. Inaddition, the rake face 32 is an inclined surface of which the height islowered toward the through-hole H. The flat surface 33 is provided in aregion closer to the through-hole H than the rake face 32. In addition,the flat surface 33 is a flat surface perpendicular to the center axis Xin the penetrating direction of the through-hole H. Here, the lowersurface 2 in the present embodiment is formed on a plane perpendicularto the center axis X.

The land surface 31 is continuous with the corner cutting edges 5 andthe main cutting edge 6 and is provided in a region closer to the centeraxis X than the corner cutting edges 5 and the main cutting edge 6. Theland surface 31 refers to a surface of a strip with a narrow widthprovided along the corner cutting edges 5 and the main cutting edge 6and is either substantially parallel to the lower surface 2 or aninclined surface of which the height is lowered toward the center. Here,in the land surface 31, a part of a region close to the corner cuttingedges 5 also includes a place where the height is increased toward thecenter.

The corner cutting edges 5 and the main cutting edge 6 are formed at aline of intersection between the land surface 31 and the lateral surface4. The land surface 31 is provided in order to increase the strength ofthe corner cutting edges 5 and the main cutting edge 6. The rake face 32located on the inner side of the land surface 31 is, as described above,an inclined surface of which the height is lowered toward the center.Therefore, the interior angle formed by the rake face 32 and the lateralsurface 4 is small. However, because the interior angle formed by theland surface 31 and the lateral surface 4 is larger than the interiorangle formed by the rake face 32 and the lateral surface 4, the strengthof the corner cutting edges 5 and the main cutting edge 6 can beincreased by including the land surface 31. Here, the width of the landsurface 31 located between the outer edge of the upper surface 3 and theouter edge of the rake face 32 is appropriately set according to thecutting conditions, but is set to a range of, for example, 0.05 to 0.5mm.

The rake face 32 is continuous with the land surface 31 and is providedin a region closer to the center axis X than the land surface 31. Therake face 32 refers to a surface on the main cutting edge 6 on which cutchips are scraped away. For this reason, the chips of the work materialflow so as to be transported over the surface of the rake face 32. Therake face 32 is an inclined surface of which the height is loweredtoward the center of the upper surface 3 in order to facilitate the chipprocessing.

Although not particularly illustrated, the inclination angle of theangle formed by the lower surface 2 in a cross-section orthogonal to therake face 32 and the rake face 32 may be set to a range of, for example,5 to 30°. Because the rake face 32 may have a height which is lowertoward the center, the rake face 32 may be configured by a plurality ofregions of which the inclination angles are different to each other, andmay be configured to have a recessed curved shape.

The flat surface 33 is continuous with the rake face 32 and is providedin a region closer to the center axis X than the rake face 32. Athrough-hole H is provided further toward the center axis X than theflat surface 33. By providing the flat surface 33, the insert 1 can befixed to the holder using a retainer (not illustrated) called a clamper.Specifically, it is possible to clamp the insert 1 using the clamper andthe holder by pressing the lower surface 2 and the flat surface 33, andthe insert 1 can be fixed between the clamper and the holder.

The lateral surface 4 is provided between the lower surface 2 and theupper surface 3. The lateral surface 4 functions as a flank surface andis connected with the outer edge of the upper surface 3. The lateralsurface 4 includes a flat part 41 with a flat shape located at a placecorresponding to the main cutting edge 6 and a curved portion 42 with acurved shape located at a place corresponding to the corner cuttingedges 5. In this manner, the lateral surface 4 includes the flat part 41continuous with the main cutting edge 6. In the flat part 41, the lengthin a direction parallel to the lower surface 2 when viewed from the sideis set to a range of, for example, 5 to 20 mm. In the flat part 41, thelength in the up and down direction when viewed from the side is set toa range of 2 to 8 mm. In addition, the curved portion 42 is located at aplace connected with the flat parts 41 located on different lateralsurfaces.

By providing the flat parts 41 on the lateral surfaces 4, it may besimply confirmed to what extent the surface of the flat parts 41 areworn in order to measure the state of the wear of the flank surface.Therefore, it is easy to measure the wear by using actual measurementsfrom a photograph or the like. Here, in the present embodiment, theentirety of the lateral surface 4 from the upper end to the lower end ofthe place corresponding to the main cutting edge 6 is set as the flatpart 41; however, the present invention is not limited thereto. Forexample, a place at a part continuous with the main cutting edge 6 maybe set as the flat part 41 and a step or the like may be provided belowthis flat part 41. The main cutting edge 6, which is a line ofintersection between the upper surface 3 and the lateral surface 4, isformed on the side part. The main cutting edge 6 has an upwardly convexshape as a whole when viewed from the side as illustrated in FIG. 4 orFIG. 5.

The insert 1 according to the present embodiment includes a rectangularshape when viewed from above and includes four side part and four cornerparts.

Two corner parts are paired to be adjacent at each side part. Therefore,the insert 1 according to the present embodiment includes four maincutting edges 6. Then, the corner cutting edges 5 are provided betweenthe main cutting edges 6 along the outer edge of the upper surface 3.Therefore, four of the corner cutting edges 5 are formed.

Here, because the insert 1 of the present embodiment has a rectangularshape when viewed from above, four of the main cutting edges 6 and fourof the corner cutting edges 5 are formed; however, the present inventionis not limited thereto. The number of the main cutting edges 6 and thecorner cutting edges 5 may, for example, be 3, 5, 6, or more dependingon the polygonal shape of the insert 1 when viewed from above.

In a cutting tool 100 illustrated in FIG. 10 using the insert 1 of thepresent embodiment, one of the four main cutting edges 6 is used in thecut processing on the work material. Here, in a case where the maincutting edge 6 being used deteriorates due to prolonged cut processing,after temporarily removing the insert 1 from a holder 101, the holder101 may be attached once more after rotating the insert 1 90° withrespect to the center axis X. Because of this, another of the unusedmain cutting edges 6 can be used in the cut processing on the workmaterial.

Although not illustrated, the line of intersection between the uppersurface 3 and the lateral surface 4 does not have a strict linear shapedue to the intersection of the two surfaces. When the line ofintersection between the upper surface 3 and the lateral surface 4 issharpened to an acute angle, the durability of the main cutting edge 6is decreased. Therefore, the portion where the upper surface 3 and thelateral surface 4 intersect may have a slightly curved surface shape,that is, may be subjected to a honing process.

As illustrated in FIG. 4 or FIG. 5, the main cutting edge 6 has anupwardly convex shape rather than a linear shape as a whole when viewedfrom the side. Specifically, the main cutting edge 6 includes thecurving portion 61 with an upwardly convex curved shape and a pair oflinear portions 62 provided to be continuous with the curving portion61. The pair of linear portions 62 respectively extend from the curvingportions 61 toward the pair of corner cutting edges 5. When the maincutting edge 6 has such a shape, in comparison with a case where themain cutting edge 6 has a linear shape parallel to the upper surface 3,the main cutting edge 6 is inclined with respect to the work material soas to easily come into contact therewith. Therefore, the work materialcan be favorably processed because it is possible to decrease thecutting resistance.

Here, out of the pair of linear portions 62 (62 a and 62 b), the linearportion extending toward the first corner cutting edge 5 a is the firstlinear portion 62 a and the linear portion extending toward the secondcorner cutting edge 5 b is the second linear portion 62 b.

Here, that the linear portion 62 extends toward the corner cutting edges5 simply has the meaning of extending toward the side at which the pairof corner cutting edges 5 a and 5 b are located rather than beinglimited to the meaning that a virtual extension line of the linearportion 62 intersects with the corner cutting edges 5. For example, inFIG. 5, because the first corner cutting edge 5 a is located on the leftend, the linear portion extending from the curving portion 61 toward theleft side is set as the first linear portion 62 a. In addition, in FIG.5, because the second corner cutting edge 5 b is located on the rightend, the linear portion extending from the curving portion 61 toward theright side is set as the second linear portion 62 b.

As long as the curving portion 61 has an upwardly convex curved shape,the shape is not particularly limited and, for example, can be set to anarc shape, an elliptical shape, or a parabolic shape. In the presentembodiment, the curving portion 61 has an upwardly convex arc shape. Insuch a case, there is less susceptibility to the influence of axial rakewhen attaching the insert 1 to the holder and the insert 1 can stablycut into the work material.

Here, description will be given assuming a case where all of the maincutting edges 6 have a linear shape. When the main cutting edges 6 ofthe insert 1 start to cut into the end surface of the work material,strong chatter vibration is generated in the insert 1. In a case whereall of the main cutting edges 6 simply have a linear shape, asillustrated in FIG. 1, depending on the angle at which the main cuttingedge 6 starts to strike the work material, the entirety of the maincutting edge 6 may start to strike the work material at the same time,and a large impact is applied to the insert 1 and vibration isgenerated, which is a factor which generates chatter vibration. Becauseit is not possible to improve the cutting conditions when chattervibration is generated, the processing efficiency cannot be improved.

In addition, assuming a case where all of the main cutting edges 6 havean upwardly convex curved shape, the main cutting edge 6 may start tostrike the work material at one point. However, when the main cuttingedge 6 starts to cut into the work material, because the total length ofthe main cutting edge 6 is increased in comparison with when all of themain cutting edges 6 have a linear shape, the time during which a strongimpact continues to be applied to the insert 1 is also increased.

In the insert 1 according to the present embodiment, the main cuttingedges 6 include the curving portion 61 with an upwardly convex curvedshape and the pair of linear portion 62 provided to be continuous withthe curving portions 61. Therefore, when starting the cutting, theentirety of the main cutting edge 6 does not strike the work materialand, furthermore, the overall length of the main cutting edge 6 can beshortened in comparison with a case where the entirety of the maincutting edge 6 has an upwardly convex curved shape. Therefore, theinsert 1 according to the present embodiment can reduce the cuttingresistance, the impact is lessened, and it is possible to controlincreases in the cutting resistance when the insert 1 starts to cut intothe work material.

In addition, as illustrated in FIG. 5, in the main cutting edge 6, thetop portion 63 which is a portion located to be uppermost in the curvingportion 61 is positioned more toward the first corner cutting edge 5 awhich, of the pair of corner cutting edges 5 (5 a and 5 b), iscontiguous to the machined surface of the work material. Specifically,in a case where the insert 1 is viewed from the side, an interval in adirection parallel to the virtual plane L between the top portion 63 andthe first corner cutting edge 5 a is shorter than an interval in adirection parallel to the virtual plane L between the top portion 63 andthe second corner cutting edge 5 b.

The top portion 63 is formed at a higher position, for example, from 0.2to 1.2 mm above the height position of the corner cutting edges 5. Then,the main cutting edge 6 has, for example, a length of 5 to 25 mm in theplanar direction of the lower surface 2 and the top portion 63 is formedto be shifted by, for example, 0.5 to 1.5 mm to the side of the firstcorner cutting edge 5 a with respect to the center position Pin thelength of the main cutting edge 6 in the planar direction. In addition,out of the pair of the linear portions 62 (62 a and 62 b), the firstlinear portion 62 a extending toward the first corner cutting edge 5 ais formed to be shorter than the second linear portion 62 b extendingtoward the second corner cutting edge 5 b.

In addition, for each of the pair of linear portions 62, when viewedfrom the side, the inclination angle of the first linear portion 62 awith respect to the virtual plane L is larger than the inclination angleof the second linear portion 62 b with respect to the virtual plane L.Specifically, the inclination angle of the first linear portion 62 a isset to from 5 to 15° and the inclination angle of the second linearportion 62 b is set to from 3 to 13°.

As illustrated in FIGS. 10 to 12, the insert 1 according to the presentembodiment is attached to the holder 101 such that a part of the firstcorner cutting edge 5 a and the main cutting edge 6 protrudes furthertoward the work material than the leading end surface of the holder 101.At this time, because the top portion 63 is located on the curvingportion 61 and is positioned more toward the first corner cutting edge 5a which is contiguous to the machined surface of the work material, itis possible to keep the place on the main cutting edge 6 which contactsthe work material small when the main cutting edge 6 starts to strikethe work material.

In addition, by providing the first linear portion from the curvingportion 61 toward the first corner cutting edge 5 a, the contact lengthcan be controlled to be short when starting to cut into the workmaterial, and it is possible to suppress chatter vibration. Furthermore,out of the pair of linear portions, because the first linear portion isshorter than the second linear portion, the contact length where thelinear portion contacts the work material can be effectively controlled,and it is possible to control increases in the cutting resistance whenthe insert 1 starts to cut into the work material.

In this manner, the main cutting edge 6 includes the curving portion 61with an upwardly convex curved shape and a pair of linear portions 62provided to be continuous with the curving portion 61. Therefore, theadvantages of both a case where the entirety of the main cutting edge 6has a linear shape and a case where the entirety of the main cuttingedge 6 has an upwardly convex curved shape are provided. Furthermore,because the top portion 63 of the curving portion 61 is positioned moretoward the first corner cutting edge 5 a which is contiguous to themachined surface of the work material, the influence because of thecutting depth of the work material is reduced such that the top portion63 can stably cut into the work material. In this manner, in the insert1 of the present embodiment, the impact is lessened when the insert 1starts to cut into the work material and it is possible to controlincreases in the cutting resistance during the cut processing.

<Modification>

Here, the present invention is not limited to the embodiments describedabove and various changes, improvements, and the like are possible in arange not departing from the gist of the present invention.

Description will be given below of a modification of the presentembodiment. Here, in a cutting insert 1 x according to the modificationof the present embodiment, the same reference numerals are applied toportions which are the same as the insert 1 according to the embodimentdescribed above and description thereof will be appropriately omitted.

FIG. 6 is an external appearance perspective diagram of the insert 1 xaccording to one modification in which a first corner cutting edge 5 axis placed in front and an upper surface 3 x is viewed from above. FIG. 7is an upper surface diagram of the insert 1 x according to themodification. FIG. 8 is an upper surface diagram of the insert 1 xaccording to the modification illustrated in FIG. 7 and illustrates ashape in a case when a main cutting edge 6 x is viewed from above. FIG.9 is a lateral surface diagram of the insert 1 x according to themodification and illustrates the shape when the main cutting edge 6 x isviewed from the side.

In the cutting insert 1 of the embodiment described above, when viewedfrom the side, the main cutting edge 6 includes the upwardly convexcurving portion 61 and includes a pair of linear portions 62 (62 a and62 b) respectively extending from the curving portion 61 toward the pairof corner cutting edges 5 (5 a and 5 b). In the embodiment describedabove, the main cutting edge 6 is configured by these sections; however,the main cutting edge 6 may further include a bent part 64.

In the same manner as the embodiment described above, the insert 1 xaccording to the modification includes a lower surface 2 x, the uppersurface 3 x, and a lateral surface 4 x, and a cutting edge is formed ata ridge where the upper surface 3 a and the lateral surface 4 xintersect. As the cutting edges, there are a corner cutting edge 5 x andthe main cutting edge 6 x in the same manner as the embodiment describedabove. Then, the main cutting edge 6 x further includes the bent part 64located between the second linear portion 62 bx and the second cornercutting edge 5 b in addition to a curving portion 61 x, a first linearportion 62 ax, and a second linear portion 62 bx. The bent part 64includes a downwardly convex shape when viewed from the side and, asillustrated in FIG. 9, is formed such that the height position in the upand down direction in the main cutting edge 6 x includes the sectionwhich is the lowermost point. Here, the lower end of the bent part 64 isset at a low position which is, for example, from 0.2 to 1.2 mm belowthe top portion 63.

In addition, as illustrated in FIG. 7 or FIG. 8, in the main cuttingedge 6 x, the bent part 64 is recessed toward the center of the uppersurface 3 x when viewed from above. Here, being recessed toward thecenter of the upper surface 3 x means being located so as to be closerto the center of the upper surface 3 x than a tangential line connectingboth of the pair of corner cutting edges 5 (5 ax and 5 bx). In the bentpart 64, an interval between the portion, which is closer to the centerof the upper surface 3 x than the tangential line described above, andthe tangential line described above is set to a range of 0.02 to 0.2 mm.

In the insert 1 x according to the present modification, the maincutting edge 6 x includes the bent part 64. Therefore, when the insert 1x is attached to the holder 101 to cut the work material, the cuttingangle on the outer peripheral side of the main cutting edge 6 x can bereduced. Because of this, during shoulder machining, the thickness ofthe chips in the vicinity of the corner cutting edges 5 can be reduced,thereby lessening the impact during cutting. Accordingly, it is possibleto improve the fracture resistance of the corner cutting edges 5 x andthe main cutting edge 6 x.

<Cutting Tool>

Next, description will be given of a cutting tool 100 of an embodimentof the present invention using FIGS. 10 to 12. FIGS. 10 to 12 illustratea state where the insert 1 is attached to an insert pocket 102 of theholder 101 using a screw 103. Here, the two-dot chain line in FIG. 10indicates the rotation center axis Y of the cutting tool 100.

As illustrated in FIGS. 10 to 12, the cutting tool 100 of the presentembodiment includes a rotation center axis Y and is provided with theholder 101 including a plurality of insert pockets 102 (simply referredto below as pockets 102) on the outer peripheral surface of the leadingend side and the inserts 1 described above, which are mounted in each ofthe pockets 102.

The holder 101 has a substantially cylindrical shape centered on therotation center axis Y. Then, outer peripheral surface of the leadingend side of the holder 101 is provided with a plurality of the pockets102. The pockets 102 are portions on which the inserts 1 are mounted andare opened to the outer peripheral surface and the leading end surfaceof the holder 101. The plurality of pockets 102 may be provided at equalintervals or unequal intervals. Because the plurality of pockets 102 areformed in the holder 101, the holder 101 does not have a strictlycylindrical shape.

Then, the inserts 1 are mounted in the plurality of pockets 102 providedin the holder 101. The plurality of inserts 1 are mounted such thatparts of the cutting edges are in front of the leading end surface ofthe holder 101, that is, protrude further toward the work material thanthe leading end surface of the holder 101. Specifically, the pluralityof inserts 1 are mounted on the holder 101 such that parts of the cornercutting edge 5 a and the main cutting edge 6 protrude from the leadingend surface of the holder 101.

At this time, the corner cutting edge 5 a is fixed at a positionprotruding the furthest from the leading end surface of the holder 101upon cutting. As illustrated in FIG. 12, the inserts 1 are mounted onthe pockets 102 such that the corner cutting edges 5 a protrude towardthe front from the leading end surface of the holder 101. Because ofthis, the top portion 63 of the curving portion 61 is attached to theholder 101 and is positioned more toward the first corner cutting edge 5a which is contiguous to the machined surface of the work material.

In addition, in the cutting tool 100 of the present embodiment, thefirst corner cutting edge 5 a of the insert 1 is located to be closer tothe rotation center axis Y than the second corner cutting edge 5 b.Therefore, the top portion 63 positioned more toward the first cornercutting edge 5 a is closer to the rotation center axis Y. Because thetop portion 63 which initially contacts the work material is closer tothe rotation center axis Y, it is possible to control the moment of theforce applied to the cutting tool 100 to be small when the insert 1 cutsinto the work material. Accordingly, the vibration of the cutting tool100 can be controlled to be small.

In the present embodiment, the insert 1 is mounted in the pocket 102using the screw 103. That is, the screw 103 is inserted into athrough-hole in the insert 1 and the leading end of the screw 103 isinserted into a screw hole (not illustrated) formed in the pocket 102such that the insert 1 is mounted on the holder 101 by fixing the screw103 into the screw hole. Here, for the holder 101, it is possible to usesteel, cast iron, or the like. In particular, it is preferable to usesteel with a high toughness in these materials.

<Method for Manufacturing a Cut Workpiece>

Next, description will be given of a method for manufacturing a cutworkpiece of one embodiment of the present invention using FIGS. 13 to15. FIGS. 13 to 15 illustrate a method for manufacturing a cutworkpiece. Here, the broken lines in FIGS. 13 to 15 illustrate therotation center axis Y of the cutting tool 100. The cut workpiece ismanufactured by carrying out cut processing on the work material. Thecutting method in the present embodiment is provided with the followingsteps. That is,

(1) rotating the cutting tool 100 represented in the embodimentdescribed above,

(2) bringing the main cutting edge 6 in the rotating cutting tool 100into contact with the work material 200, and

(3) moving the cutting tool 100 away from the work material 200,

are provided.

More specifically, first, the cutting tool 100 is brought relativelyclose to the work material 200 while being rotated about the rotationcenter axis Y. Next, as illustrated in FIGS. 13 and 14, the main cuttingedge 6 of the cutting tool 100 is brought into contact with the workmaterial 200 to cut the work material 200. Then, as illustrated in FIG.15, the cutting tool 100 is moved away relative to the work material200.

In the present embodiment, the work material 200 is fixed and thecutting tool 100 is brought to be close to the work material 200. Inaddition, in FIGS. 13 and 14, the work material 200 is fixed and thecutting tool 100 is rotated about the rotation center axis Y. Inaddition, in FIG. 15, the work material 200 is fixed and the cuttingtool 100 is moved away. Here, in the cut processing in the method of thepresent embodiment, in each of these steps, the work material 200 isfixed and the cutting tool 100 is moved; however, the present inventionis of course not limited thereto.

For example, in step (1), the work material 200 may be brought close tothe cutting tool 100. In the same manner, in step (3), the work material200 may be moved away from the cutting tool 100. In a case where the cutprocessing is to be continued, steps of bringing the main cutting edge 6of the insert 1 into contact with different places on the work material200 may be repeated by maintaining the rotating state of the cuttingtool 100. When the main cutting edge 6 being used is worn, an unusedmain cutting edge 6 may be used by rotating the insert 1 90° withrespect to the center axis of the through-hole. Here, representativeexamples of the material of the work material 200 include carbon steel,alloy steel, stainless steel, cast iron, non-ferrous metals, or thelike.

REFERENCE SIGNS LIST

-   1, 1 x, 10 Cutting insert (insert)-   2, 2 x Lower surface-   3, 3 x Upper surface-   31 Land surface-   32 Rake face-   33 Flat surface-   4, 4 x Lateral surface-   41 Flat part-   42 Curved portion-   5, 5 x Corner cutting edge-   5 a, 5 ax First corner cutting edge-   5 b, 5 bx Second corner cutting edge-   6, 6 x Main cutting edge-   61, 61 x Curving portion-   62 Linear portion-   62 a, 62 ax First linear portion-   62 b, 62 bx Second linear portion-   63 Top portion-   64 Bent part-   100 Cutting tool-   101 Holder-   102 Insert pocket (pocket)-   103 Screw-   200 Work material-   S End surface-   e1 Ridge-   H Through-hole-   X Center axis-   Y Rotation center axis-   L Virtual plane-   P Center of main cutting edge

The invention claimed is:
 1. A cutting insert comprising: an uppersurface with a polygonal shape comprising: a first corner which iscontiguous to a machined surface of a work material during cutting ofthe work material; a second corner; and an edge located between thefirst corner and the second corner; a lower surface with a polygonalshape located opposite to the upper surface; a lateral surface providedbetween the lower surface and the upper surface, and comprising: a firstcurved part having a curved shape; a second curved part having a curvedshape; and a flat part having a flat shape; a first corner cutting edgelocated at the first corner and connected to the first curved part; asecond corner cutting edge located at the second corner and connected tothe second curved part; and a main cutting edge located in the edge andconnected to the flat part, wherein the main cutting edge is upwardlyconvex in shape and comprises: an upwardly convex curving portion; afirst linear portion extending from the curving portion toward the firstcorner cutting edge; and a second linear portion extending from thecurving portion toward the second corner cutting edge, and a top portionof the curving portion is closer to the first corner than the secondcorner.
 2. The cutting insert according to claim 1, wherein the curvingportion has an arc shape in a side view.
 3. The cutting insert accordingto claim 1, wherein the second linear portion is longer than the firstlinear portion.
 4. The cutting insert according to claim 3, wherein aninclination angle of the first linear portion with respect to a virtualplane perpendicular to a center axis connecting a center of the uppersurface and a center of the lower surface is greater than an inclinationangle of the second linear portion with respect to the virtual plane ina side view.
 5. The cutting insert according to claim 1, wherein themain cutting edge further comprises a downwardly concave bent part in aside view located between the second linear portion and the secondcorner cutting edge.
 6. The cutting insert according to claim 5, whereinin the main cutting edge, the bent part is recessed toward the center ofthe upper surface in a top view.
 7. A cutting tool comprising: a holdercomprising a plurality of insert pockets on a leading end side; and thecutting insert described claim 1, which is mounted in the insert pocketssuch that the main cutting edge protrudes from the holder.
 8. A methodfor manufacturing a cut workpiece, the method comprising the steps of:rotating the cutting tool described in claim 7; bringing the maincutting edge in the rotating cutting tool into contact with a workmaterial; and separating the cutting tool from the work material.
 9. Thecutting insert according to claim 1, wherein the first corner cuttingedge has a downwardly concave curved shape in a side view.